KTA (SARAWAK) SDN BHD (53003-D) Consulting Engineers - Jurutera Perunding MEMORANDUM To: Road Section (Attn: Ir Norman Chai) Date: 5 November 2018 From Resource Centre et _16/i¢)4- a0 STANDARD SPECIFICATION FOR ROAD WORKS Resource Centre had purchased and downloaded the updated versions of the Standard Specification for Road Works, and a copy of these documents is enclosed herewith for your keeping in Road Section: * Standard Specification for Road Works (amendment to Addendum and Section 5 — Portland Cement Conerete Pavement); ee Section 1: General; re ce OP) Section 2: Earthworks; OFFICE, cor vy Section 3: Drainage Works; mn Section 4: Flexible Pavement; Section 6: Road Furniture — Sub-Section 6.3: Road Markings; Section 7: Road Lighting; Section 8: Traffic Signal System; Section 9: Concrete; Section 10: Piling Works; Section 11: Prestressing for Structures; Section 13: Bridge Bearings; Section 14: Expansion Joints; Section 15: Parapets; Section 16: Slope Stabilisation; Section 17: Site Investigation; Section 19: Traffic Management at Work Zone; Section 21: Traffic Diversion and Management, Section 23: Geotechnical Works; Section 24: Geotechnical Instrumentation; Section 25: Pile Testing; Section 27: Joints Filler Testing; Section 28: Environmental Protection and Enhancement; Section 29: Rain Gauge and SMS Remote Terminal Unit (RTU); and Section 30: Special Requirements in relation to Drainage And Irrigation Department. We also purchased the following Standard Drawings for Road Works, and a copy of these documents is enclosed herewith for keeping in Road Section: * Section 3: Drainage Works; * Section 6: Road Furniture; tion 7: Road Lighting; and © Section 9: Motorcycle Lane. wee ww ew eee he eee eee eee ey ‘Thank you. Regards, BONG SIAK KHIUN, cc Bridge Section, Ir Michael Hii for yoprr informationOFFICE COPY IKRISPINGBS TKR 20401-0017-88 KERAJAAN MALAYSIA JABATAN KERJA RAYA MALAYSIA STANDARD SPECIFICATION FOR ROAD WORKS CAWANGAN JALAN, KETUA PENGARAH KERIA RAYA IBU PEIABAT JABATAN KERJA RAYA. JABATAN KERJA RAYA MALAYSIA. JALAN SULTAN SALAHUDDIN, JALAN SULTAN SALAHUDDIN. ‘50582 KUALA LUMPUR 50582 KUALA LUMPURADDENDUM NO. 2 This Addendum shall be made part of the ‘JKR Standard Specification For Road Works’ 6.25.5 Sign Faces Sign faces for permanent traffic signs shall be as shown on the Drawings and shall comply with the Malaysian Standard Specification for Reflective Sign Face Materials (MS 1216). All retroreflective sheeting shall be fixed in accordance with the ‘manufacturer's instructions. Unless otherwise agreed by the S.O., sign faces shall be formed from a single piece of retroreflective sheeting. Where, with the agreement of the $.0., more than one retroreflective sheeting is used, the number of sheets shall be kept to a minimum. All faces up to. 1 m in size shall be produced with a single sheet and no joint will be accepted. Only vertical and horizontal joints shall be permitted and all joints in retroreflective sheeting shall be overlapped by not less than 6 mm. The overlap in the horizontal joints shall be from the top and the vertical joints shall be from the left; butt joints will only be accepted for prismatic retroreflective sheeting. Retroreflective sheeting shall be applied evenly over the whole surface of the sign plate and shall adhere fully. It shall be free from twists, cracks, folds or cuts, air bubbles and other blemishes. All retroreflective sheetings used on the same sign shall be carefully matched for colour to produce a uniform appearance both by day and by night, Non-uniform shades of colour on any one sign will not be accepted. The edges of all the retroreflective sheeting shall be properly fitted to ensure no delimination of the sheeting from the base substrate. Where sheeting is applied to extruded sections by pressure roller, it shall extend over the top and bottom edges of these sections by not less than 3 mm. Any cut-out letters, numerals, symbols and borders shall be of material compatible with the sheeting to which they are applied. They shall be applied in accordance with the sheeting manufacturer's instructions.The finish of all sign faces shall be capable of passing the tests described in MS 1216, and the standards of fabrication and workmanship shall be such that under normal conditions of service and proper maintenance, the sign faces shall last not less than 5 years without any serious blemishes or defects for Engineering Grade retroreflective sheeting and 8 years for High Intensity and prismatic retroreflective sheeting. ‘The Contractor shall furnish to the $.O. a letter of warranty for the specified period for all sign faces from the manufacturer of the sheeting or the sign fabricator. ‘The retroreflective sheeting manufacturer shall furnish to the $.0. written warranty that the fluorescent colours shall be durable for a minimum 7 years for permanent signs and a minimum 3 years for temporary signs.ADDENDUM NO. 3 This Addendum shall be made part of the ‘JKR Standard Specification For Road Works” FLUORESCENT ORANGE WIDE ANGLE PRISMATIC RETROREFLECTIVE SHEETING FOR THE WORK ZONE 6.2.6.1.1 Description The fluorescent orange wide angle prismatic retroreflective sheeting is specifically designed for use on rigid substrate work zone signs to provide high visual impact under nighttime and daytime driving conditions, including low visibility periods such as dawn, dusk, and overcast days. The sheeting shall consist of prismatic lenses formed in a transparent fluorescent orange synthetic resin, sealed, and backed with an aggressive pressure sensitive adhesive protected by a removable liner. The sheeting shall have a smooth surface with a distinctive interlocking diamond seal pattern and orientation marks visible from the face. 6.2.6.1.2 Requirements i) Photometric - Coefficient of Retroreflection RA. When the sheeting applied on aluminum test panels is measured in accordance with ASTM E 810, it shall have minimum coefficient of retroreflection values as shown in Table I. The rotation angle shall be *90°, the observation angles shall be 0.2° and 0.5°, the entrance angles (component 8!) shall be ~4°, +30°, and +50°, and the entrance angle component 82 = 0°, TABLEI Minimum Coefficient of Retroreflection RA (Candelas per footcandle per square foot) (90° Rotation Angle*) Observation Entrance Angle (°) Angle (°) Orange 02 “4 200 0.2 430 120 02 +50 50 0.5 4 80 05 +80 50 05 +50 20 * ‘The datum mark (arrow) imprinted on the face of the sheeting shalll be the datum mark for test purposes. For the specified 90° rotation angle, the sheeting shall be positioned on the goniometer so that the direction of this datum mark is perpendicular to the observation plane (this geometry is equivalent to a 90° orientation angle with a presentation angle of 0 in the measurement geometry described in Fed. Test Method Standard 370).fi) Daytime Color Color shall conform to the requirements of Tables II. Daytime color and maximum spectral radiance factor (peak reflectance) of sheeting mounted on aluminum test panels shall be determined instrumentally in accordance with ASTM E 991. The values shall be determined on a HunterLab Labscan 6000 0/45 Spectrocolorimeter with option CMR 559 [or approved equal 0/45 (45/0) instrument with circumferential viewing (illumination)]. Computations shall be done in accordance with ASTM E 308 for the 2° observer. ~ TABLE Il ~ Color Specification Limits** (Daytime) Color T z 3 4 Reflectance Limit ¥ (%) x Y x ¥ x ¥ x Y__| Min. [ Max. Orange | 583 | 416 | 523 | 397 | soo | 360 | 631 | 369 | 30 | - (New) Orange | 583 | 416 | 523 | 397 | 560 | 360 | 631 | 369 | 20 | 45 (Weathered) Maximum spectral radiance factor, new: 110%, min, weathered: 60%, min, "** The four pairs of chromaticity coordinates determine the acceptable color in terms of the CIE 1931 standard colorimetric system measured with standard illuminant D653. iii) Nighttime Color. Nighttime color of the sheeting applied to aluminum test panels shall be determined instrumentally in accordance with ASTM F 811 and calculated in the u’, v' coordinate system in accordance with ASTM E 308. Sheeting shall be measured at 0.33° observation and -4° entrance at 90° rotation. Color shail conform to the requirements of Table III. TABLE Ill Color Specification Limits** (Nighttime) Color 1 2. 3 4 we v wl v Ww v vv Orange 400 | 540 | 475 | S29 | aas | 522 | 372 | 334 (new and weathered)vii) Resistance to Accelerated Weathering. The retroreflective surface of the sheeting shall be weather resistant and show no appreciable cracking, blistering, crazing, or dimensional change after 1 year's unprotected outdoor exposure in south Florida, south-facing and inclined 45° from the vertical, or after 1500 hours' exposure in a xenon arc weatherometer in accordance with ASTM G 26, Type B, Method A. Following exposure, panels shall be washed in a. 5% HCL solution for 45 seconds, rinsed thoroughly with clean water, blotted with a soft clean cloth and brought to equilibrium at standard conditions. After cleaning, the coefficient of retroreflection shall be not less than 100 when measured as in D.2, below, and the color is expected conform to the requirements of Tables II and [fl for weathered sheeting. The sample shall: a) Show “ho appreciable evidence of cracking, scaling, pitting, blistering, edge lifting or curling or more than 1/32 inch (0.08 cm) shrinkage or expansion. b) Be measured only at angles of 0.2° observation, -4° entrance and 90° rotation. Where more than one panel of a color is measured, the coefficient of retroreflection shall be the average of all determinations. Impact Resistance. ‘The retroreflective sheeting applied according to the sheeting manufacturer's recommendations to a test panel of alloy 6061-T6, 0.040" (0.10 cm) by 3" (7.6 em) by 5" (12.7 cm) and conditioned for 24 hours, shall show no cracking outside the impact area when the face of the panel is subjected to an impact of 100 inch-pounds (11.3 Nim) using a weight with a 5/8 in. (15.8 mm) diameter rounded tip dropped froma height necessary to generate an impact of 100 inch-pounds, at test temperatures of both 32° F (O° C) and 72° F (22°C). Resistance to Heat, The retroreflective sheeting, applied to a test panel as in E., above, and conditioned for 24 hours, shall be measured in accordance with paragraph. A. at 0.2° observation and -4° entrance angles at 90° rotation and exposed to 170 + 5° F (77 +3° C) for 24 hours in an air circulating oven. After heat exposure the sheeting shall retain a minimum of 70% of the original coefficient of retroreflection. Field Performance. Retroreflective sheeting processed and applied to sign blank materials in accordance with the sheeting manufacturer's recommendations, is expected to perform effectively for a minimum of 3 years. The retroreflective sheeting will be considered unsatisfactory if it has deteriorated due to natural causes to the extent that: (1) the sign is ineffective for its intended purpose when viewed from a moving vehicle under normal day and night driving conditions; or (2) the coefficient of retroreflection is less than 100 when measured at 0.2° observation and -4° entrance at 90° rotation. All measurements shall be made after sign cleaning according to the sheeting manufacturer's recommendations.STANDARD SPECIFICATION FOR ROAD WORKS CONTENT -SECTION 7 ——Genera oerceder oy reel eespeis Et] ‘SECTION? Earthworks [Superceded By JKRvSPs2013-52 [sot SecnoNs Dane Wat Sgrceery Tae SREFION-4 ——Fioibe Pavement [superceded By skRvsPuz008-S4 J-L SECTION 5 Portland Cement Concrete Pavement SSL S61 SECTION 6 Road Fonte Sfrenterd -SRETION-7 _—Steeot-Lighting_-|Superceded By JKRISPJ/2011-87 S71 SEGFION-6 ‘Traffic Signals |Superceded By JKR/SPJ/2008-58 S81 “SECTION-9——€onerete— | Superceded By JKR/SP1/2008-S9 -SECTIONTIU-——Pling Works [Superceded By JKRVSPI2010-S10 SOL 10-1 PAGE to to to to to (KR /SP5/1988) sian S214 8-27 39-30 $1031ADDENDUM —NOs—E— [Dibatakkan This Addendum shall be made part of the ‘JKR Standard Specification For Road Works’ 1, Table 4.8 - Gradation Limits For Asphaltic Concrete Clause 4.2.4.2, page S4 - 21 should read as follows: Mix ‘Type Wearing Course | Binder Course Mix Designation ACW 20 ACB 28 B.S. Sieve % Passing by weight 37.5 mm 100 28.0 mm 100 80 - 100 20.0 mm 76 - 100 72 - 93 14.0 mm 64 - 89 58 - 82 10.0 mm 56 - 61 50 - 75 5.0 mm 46 - 71 36 - 58 3.35 mm 32 - 58 30 - 52 1.18 mm 20 - 42 18 - 38 425 um 12 - 28 ll- 25 150 um 6- 16 5- 14 75 um a- 8 3- 8 2. Table 4.9 -~ Design Bitumen Contents , Clause 4.2.4.3, page S4 - 23 should read as . follows: ACW 20 - Wearing Course 4.5 - 6.5% ACB 28 - Binder Course 4.0 - 6.0SECTION 5- PORTLAND CEMENT CONCRETE PAVEMENT(IKR/SPJ/1988) SECTION 5 - PORTLAND CEMENT CONCRETE PAVEMENT Page 5a DESCRIPTION s5-1 52. MATERIALS s5-1 S24 Cement S5-1 522 Aggregate 85-1 523 Joint Filler 85-1 524 Joint Sealants and Seals 85-1 525 ‘Waterproof Membrane 85-2 526 Caring Materials 85-2 53 PRODUCTION OF CONCRETE 53.1 Concrete 85-4 532 Equipment 85-4 54 CONSTRUCTION SAL Preparation of Subgrade or Subbase 85-4 542 Construction by Machine 85-4 5421 Fixed Forms, Rails and Guide Wires For Machine Construction 85-4 5422 Construction by Fixed Form Paving Machine 5-5 5423 Construction by Slip Form Paving Machine 5-6 543 Construction by Hand-Guided Method 85-7 SAA Manual Construction 5-8 S441 Side Forms For Manual Construction 85-9 55 JOINTS $5 - 10 S51 ‘Transverse Expansion Joints 85 - 10 552 ‘Transverse Contraction Joints 85 - 10 5524 Planes of Weakness $5 - 11 5522 Load Transfer Assemblies 85-11 553 Longitudinal Joints 5-11 SSA ‘Transverse Construction Joints 8S - 11 555 Scaling Joints 85-12 556 Concrete Saw 85 - 12 56 SURFACE TEXTURE 561 Texture of Running Surfaces 5-3 562 ‘Measurement of Texture Depth : Sand Patch Method S621 ‘Apparatus 85-13 5622 Method 85-13 57 ROUNDING OF EDGES 85-14 58 CURING S5- 14 59 REMOVING FORMS 85-15 50 OPENING TO TRAFFIC $5 - 15 SAL ‘TREATMENT OF MANHOLES AND GULLIES S85 - 15(IKR/SPJ/1988) e Suz HORIZONTAL ALIGNMENTS, SURFACE LEVELS AND SURFACE REGULARITY SS - 165a 52 524 522 523 524 (aKR/SP3/1988) SECTION 5 - PORTLAND CEMENT CONCRETE PAVEMENT DESCRIPTION “This work shall consist of constructing a Portland cement concrete pavement with or without reinforcement in accordance with this Specification, including all relevant requirements of Section 9, and in conformity with the lines, levels, grades, dimensions and cross-sections shown on the Drawings. Portland cement concrete shall consist of a mixture of Portland cement, fine aggregate, coarse aggregate and water, with or without admixture, MATERIALS ‘All materials shall conform to the relevant requirements in Section 9 of this Specification. In addition the following requirements shall also be complied with, Lement Cement shall be ordinary Portland cement unless otherwise shown on the Drawings or directed by the S.O. Aggrogate Coarse aggregate to be used for at least the top 50 mm of the slab shall have a polished stone value of not less than 40. Joint Filler ‘The expansion joint filler shall conform to the requirements of AASHTO M153 or M2i3. Joint Sealants and Seals Joint sealants. shall consist of hot or cold-poured compounds or preformed seals as indicated on the Drawings and shall comply with the following requirement: (®) — Hot-Poured Sealants Hot-poured sealants shall comply with the requirements of B.S. 2499 for Type ‘A2 sealants. (b) — Cold-Poured Sealants Cold-poured sealants shall comply with the performance requirements for the ‘Normal type of sealant given in B.S. 5212. ‘The sealant shall be composed of a curing agent and a base resin, which shall be in such proportions as recommended by the manufacturer to provide a fast ‘eure if the material is mixed and appliod by special machines, or a retarded ‘cure if mixed by hand. It shall cure within I hour and remain active for not less than 4 hours. The sealant shall be applied after the curing period of the primer and within the period that the primer remains active. Materials to be mixed and applied by hand shall be supplied in separate containers and shall be mixed in the correct proportions using a powered stitrer cor mixer o any other method approved by the $.O. 85-1(IKR/SPI/1988) (© Gunning Grade Sealants Gunning grade sealants consisting of two-part poly-sulphide-based sealing compounds shall comply with B.S. 4254. Alternatively, poly-urcthane-based sealing compounds may be used provided their performance is not inferior to BS. 4254 material. (@ Preformed Compression Seals Preformed compression seals shall be made from natural rubber and shall conform to the requirements contained in Table 5.1 525 jerproof Mem Plastic sheeting shall have a minimum thickness of 125 um and shall be of quality as approved by the S.O. 526 Curing Materials ‘The exposed surface of concrete pavements shall be curéd immediately after the surface treatment by the application of one of the following curing materials :- (3) White Pigmented Liquid Menbrane Fomig "Compound White pigmented liquid membrane-forming compound shall conform to the ‘requirements of AASHTO M148, Type 2. (&) — Aluminised Curing Compound Aluminised curing compound shall be stable and impervious to evaporation of water from the concrete surface within 60 minutes after application, It shall have test certifigates from an approved testing laboratory to show that the compound has a curing efficiency of 90%. ‘The curing compound shall contain sufficient flaked aluminium in finely divided dispersion to produce complete coverage of the sprayed surface with a metallic finish. The curing compound shall not react chemically with the concrete to be cured and shall not crack, peel or disintegfaté within 2 weeks after application. :(IKR/SPI/1988) ‘TABLE 5.1 - SPECIFICATION FOR PREFORMED NATURAL RUBBER COMPRESSION SEALS Property. Units | Requirement Hardness. IRHD 5545 Tensile Strength, minimum. MPa 6 Elongation at break, minimum. % 400 ‘Compression Set, 24 hours at 100 °C, maximum. % 40 ‘Ageing Resistance, maximum change from unaged values after ‘Tahrs + Ohrs at 100°C: = Dhrs - hardness RD | Oto +10 + tensile strength % -20 + elongation at break. % =25 ‘Ozone Resistance, 20% clongation, 96 hours at 140 °C, 50 pphm. - No cracking Change ia Volume after immersion in water for 7 days at laboratory temperature, maximum. % Oto +5 Recovery of Finished Seals, under 50% deflection, after Tabs + Ohrs at 100°C. % 85 - 2 hrs Note : All tests are in accordance with ISO Standards, 85-353 54 S531 532 Sad 5A2 SA21 (SKR/SPI/1988) PRODUCTION OF CONCRETE Concrete Concrete shall be of the grade shown on the Drawings and shall comply with the relevant requirements of Section 9 of this Specification. Equipment All equipment used such as batching plant and mixers shall comply with the relevant requirements of Section 9 of this Specification. CONSTRUCTION Preparation of Subgrade or Subbase Prior to placing concrete pavement, the underlying subgrade or subbase shall have been shaped and compacted in accordance with the provisions of Sub-Sections 2.2.7 or 4.1.28 appropriate and the waterproof membrane laid as required in the Drawings. ‘Notwithstanding any earlier approval of finished subgrade or subbase, any daniage to or deterioration of the subgrade or subbase shall be made good to the satisfaction of the S.O. before the waterproof membrane is laid and the conerete pavement constructed. struction by Machi ‘The concrete slab shall be constructed cither by fixed form or by slip form paving plant in a continuous process in either one or two layers, as approved by the S.0. Prior to the placing of concrete, all of the required joint assemblies such as dowel bars, tie bars, etc, shall be installed in accordance with the requirements of Sub-Section 5.3, In one-layer construction, the slab reinforecment shall also be installed and fixed in accordance with the relevant requirements of Section 9. In two-layer construction, the thickness of the top layer shall be not less than 50mm or twice the maximum size of the coarse aggregate, whichever is the greater, and shall be at least 15 mm thicker than the depth of the groove former, if used. Placement of reinforcement and concreting of the top layer shall be done immediately, and in any case not more than 30 minutes, after the completion of the bottom layer, Fixed Forms. Rails and Guide Wires. For Machine Construction (a) ° Flked-Forms and Rails Alll forms and rails shall be made of steel and be sufficiently robust and rigid fo support the weight and pressure caused by the paving equipment. Side forms for use with wheeled paving machines shall incorporate metal rails firmly fixed at a constant height below the top of the forms. ‘The forms shall be secured by using not less than three pins for each 3 m length, having one pin fixed at each side of every joint. Forms shall be tightly jpined together by a locked joint, free from play or movement in any direction. S5-4(JKR/SP3/1988) Forms stall be cleaned and oiled immediately before cach use. The rails or running surfaces shall be kept clean in front of the wheels of any paving machines. ‘The forms shall be straight within a tolerance of 3mm in 3 m. ‘The forms shall be bedded on low moisture content cement mortar and set to the pavement surface level as described in the Contract within a tolerance of 3mm. The bedding shall not extend under the slab. ‘There shall be no vertical step between the ends of adjacent forms greater than 3 mm. ‘The horizontal alignment for forms shall be to the required alignment of the pavement edgo as described in the Contract within a tolerance of + 10 mm. ‘The mortar or concrete bedding shall be broken out after use, Prior to concreting, the forms shall be approved by the S.O. Forms shall not be removed earlier than 6 hours after the completion of the ‘construction ofthe slab. Care shall be taken to prevent damage to the concrete and any projecting tie bars during the removal of the forms. If the removal of forms results in any damage to the concrete the period of 6 hours shall be increased to that which is necessary to avoid further damage and the Contractor shall make good the damaged areas. (0) Guide Wires ‘Unless otherwise agreed by the S.0., a guide wire shall be provided along each side of the slab to be constructed by slip form paving plant. Each guide wire shall be at a constant height above and parallel to the required edges of the slab within a vertical tolerance of + 3mm, In addition, one of the wires shall be at a constant horizontal distance from the required edge of the pavement within a lateral tolerance of + 10 mm, "The’guide wires shall be supported from stakes not more than 8 m apart by connectors capable of fine horizontal and vertical adjustment. ‘The guide wire shall be tensioned on the stakes so that a 500 gramme weight shall produce a deflection of not more than 20 mm when suspended at the mid-point between any pair of stakes. The ends of the guide wires shall be anchored to fixing points which shall be not closer to the edge of the slab than the row of stakes and in no circumstances shall a guide wire be anchored to a stake. ‘The stakes and guide wires shall be-checked and approved by the S.O. prior to concreting. : 5422 Construction by Fisod Form Paving Machine A fixed form paving train shall consist of separate powered machines which spread, compact and finish the concrete in a continuous operation, Conerete shall be discharged without segregation into a hopper spreader which is equipped with the means to control its. rate of deposition on to the subbase or on to the lower layer. The concrete shall be spread in cach layer without ‘segregation and to a uniform uncompacted density over the whole area of the slab. ‘The deposited concrete shall be struck off to the necessary level by the underside of the hopper a’ itis traversed across the spreading machine, ‘The ‘machine shall be eapable of being rapidly adjusted for changes in average and differential surcharge necessitated by changes in slab thickness or crossfall.(GKR/SPJ/1988) Prior to being compacted, the surface level of each loose spread layer shall be adjusted to the correct surcharge by means of rotating strike off blades or a serew device, ‘The concrete shall be compacied by vibration or by a combination of vibration and mechanical tamping so as to comply with Sub-Section 5.3.1 throughout the full depth of the slab. Poker vibrators shall be used adjacent to the side forms and the edge of previously constructed slabs. ‘The initial regulation: and finish to the surface of the slab shall be effected by means of a beam oscillating transverscly or obliquely to the longitudinal axis of the pavement. This beam shall be readily adjustable for both height and tilt. Joint grooves shall be constructed in compliance with Sub-Section 5.5. ‘The concrete shall be recompacted around the former by a hand held vibrating plate compactor dravn along, or on each side of the joint, prior to regulation of the surface by the diagonal finishing beam. ‘Tho regulation and finishing of the surface of the slab shall be carried out by a machine which incorporates twin oblique oscillating finishing beams which shall be readily adjustable for both height and tilt. ‘The beams shall weigh not less than 170 kg per linear metre, be of rectangular section and span the full ‘width of the slab, ‘The leading beam shall be vibrated. The beams shall be supported on a carriage, the level of which shall be controlled by the average level of not less than four points evenly spaced over. at least 3.5 m of the supporting rail, beam, or slab, on each side of the slab that is being constructed. The final r mn and surface finishing of the slab shall be carried out after any wet forming of joint grooves. After the final regulation and before texture is applied, any excess concrete on top of the groove former shall be removed. Whon a concrete slab is constructed in more than one width, flanged wheels on the paving machines shall not be run directly on the’ surface of any completed part of the slab. ‘The second or subsequent slabs shall be constructed either by supporting machines with flanged wheels on flat-bottom section rails weighing not less than 15 kg/m laid on the surface of the completed slab, or by replacing the flanged wheels on that side of the machine by smooth flangeless wheels. Before flangcless wheels or rails are uscd, the surface regularity of the slaly over which they are to pass shall comply with ‘Sub-Section 5.4.1 and its surface shall be thoroughly cleaned and brushed to remove all extraneous matter. Flangeless wheels or rails shall be positioned sufficiently far from the edge of the slab to avoid damage to that edge. 5423. Construction by Slip Form Paving Machine ‘A slip form ‘paving, train shall copsist of powered machines which’ spread, compact and finish the concrete in a continuous operation. A slip form paving machine shall compact the concrete by internal vibration and shape it between sliding side forms or over fixed side forms by means of either « conforming plate of by vibrating and oscillating finishing beams. ‘The concrete shall be deposited without segregation in front of the slip form paver across its whole width and to a height which at all times is in excess of the required surcharge. The deposited concrete shall be struck off to the necessary average and differential surcharge by means of a strike-off plate or a serew auger device extending across. the whole width of the slab. ‘The 85-6(TKR/SP3/1988) + equipment for striking off the concrete shall be capable of being rapidly adjusted for changes in the average and differential surcharge necessitated by changes in slab thickness or crossfall. ‘The level of the conforming plate and finishing beams shall be controlled automatically from the guide wires by sensors attached at the four corners of the slip form paving machine. ‘The alignment of the paver shall be controlled automatically from the guide wires by at least one sensor attached to the paver. ‘The alignment and level of ancillary machines for finishing, texturing and curing of the concrete shall be automatically controlled relative to the guide wires or to the surface and edge of the slab. Slip form paving machines shall have vibration of variable output, with a ‘maximum energy output of not less than 2.5 KW per metre of slab per 300. mm depth of slab for a laying speed of up to. 15 m per minute or pro rata for higher speeds, ‘The machines shall be of sufficient mass to provide adequate reaction on the traction units to maintain forward movements during the placing of concrete in all situations. Joint grooves shall be constructed in compliance with Sub-Section 5.5. The ‘concrete shall be compacted around the former by a separate vibrating plate compactor with twin plates. ‘The groove former shall be compacted to the correct level by another vibrating float which may be included with the transverse joint finishing beam. In addition a hand held vibrating float, at least 1m wide, shall be drawn over the surface along the joint. Any excess concrete ‘on top of the groove former shall be removed before the surface is textured. ‘Where a concrete surface slab is constructed in more thay one width or where the edge:needs to be matched for level to another section of surface slab, and the surface levels at the edges are not achieved, paving shall be carried out over separate fixed side forms supporting the edge to the required levels. 543, Construction by Hand-Guided Method ‘Areas to be constructed by hand-guided method shall be agreed with the S.0. ‘The siabs shall be constructed in one layer. Dowel bars, tie bars and reinforcement, if specified, shall be fitted in position as shown on the Drawings. » "The concrete shall be spread uniformly without segregation or varying degrees of precompaction, by conveyor, chute or by other means,approved by the $.O. ‘The concrete shall be struck off by a sereed so that the.average and differential surcharge is sufficient to ensure that-after compaction the surface is to the required level. ‘The concrete shall be compacted by vibrating finishing beams. In addition, internal poker vibration shall be used for slabs thicker than 200 mm and may bbe used for lesser thicknesses. When used, the pokers shall be-at points not motgsthan 500 mm. apart.over the whole area of theslab, and adjacent to the side.forms or the edge of a previously constructed slab. ‘The surface shall be regulated and finished to the level of the top of the forms or adjacent slab or pavement layer by using twin vibrating finishing beams, The beams shall be metal with a contagt face at least’50.mm wide and a vibrating ‘unit having a minimum centrifugal force of 4 kN with a frequency recommended by the manufacturer or an equivalent compactive effort. The vibrating beams shall be moved forward at a steady speed of 0.5 m to 1m et minute whist vibrating over the eompaeted surface to produce a smooth 85-7(JKR/SPI/1988) Details of joints shall be as shown on the Drawings. Joint grooves shall be constructed in compliance with Sub-Section 5.5. Any irrogularitics at wet formed joint grooves shall be rectified by means of a vibrating float at least 1.0 m wide drawn along the line of the joint. The whole area of the slab shall be regulated by two passes of a scraping straight edge not less than 1.8m wide or by a further application of a twin vibrating finishing beam. Any excess ‘concrete on top of the groove former. shall be removed before the surface is textured. ‘The surface shall be brush-textured as described in Sub-Section 5.6. ‘The concrete shall be cured in compliance with Sub-Section 5.8. 544 1 Construction Areas to be constructed by manual method shall be agreed with the S.O. The slabs shall be constructed in one layer. Dowel bars, tie bars and reinforcement, if specified, shall be fixed in position as shown on the Drawings. ‘The concrete shall be spread uniformly without segregation or varying degrees of pre-compaction, by conveyor, chute or by other means approved by the S.0. The concrete shall be struck off by a screed so that the average and differential surcharge is sufficient to ensure that after compaction the surface is to the required level. ‘The concrete shall be compacted by internal poker vibrator or other means approved by the S.. The vibrations shall be af points not more than 500 mm apart over the whole area of the slab, and adjacent to the side forms or the edge of a previously constructed slab. ‘The surface shall be regulated and finished to the level of the top of the forms or adjacent slab or pavement layer by using an approved portable hand screed. The screed shall be at least 600 mm longer than the width of the slab to be struck off and compacted. It shall be of approved shape, sufficiently rigid to retain its shape and constructed either of metal or of other material shod with metal. ‘Compaction shall be attained by raising and dropping the screed in successive positions until the required compaction and reduction of surface voids is secured. ‘The screed shall then be placed on the forms and sii along them, without lifting, in a combined longitudinal and transverse shearing motion moving always in the direction in which the work is progressing. If necessary, this shall be repeated wnt the surface is of usiform texture, true fo grads and contour, and free from porous areas. Affer the concrete has been struck off and compacted, it shall be further smoothed, sereeded and compacted by means of a longitudinal hand float or ‘other equipment as approved by the $.0. Details of joints shall be as shown on the Drawings. Joint grooves shall be constructed in compliance with Sub-Scction 5.5. Any irregularities at wet formed joint grooves shall be rectified by suitable means approved by the $.0. ‘As soon as surplus water has risen to the surface, the pavement shall be given 1 broomed finish 85-8(IKR/SP3/1988) ‘The concrete shall be cured in compliance with Sub-Section 5.8. Saat ‘Side Forms for Manual Construction Alll side forms shall be made’ of steel and be sufficiently robust and rigid to ‘withstand construction forces. ‘Timber forms shall only be used for work which is less than 200 m in length. ‘The forms shall comply with other requirements of Sub-Section 5.42.1 as appropriate.(JKR/SPI/1988) 55 JOINTS Joints shall be constructed as specified herein and /or as directed or approved by the $.0. Before’ any joint materials are set in place, the underlying Pavement course at those locations shall have been approved by the $.0. Proformed expansion joint filler shall be placed around each structure which extends into or through the pavement over the full interface with the concrete + pavement slab before concrete is placed. : 554 Transverse Expansion Joints The components for each transverse expansion joint shall be assembled in advance und placed in position as a unit. Bach assembly shall consist of an installing template, preformed joint filler of the required dimensions in a single piece, dowel ‘bars and sleeves of the required sizes and lengths atthe required locations, and spacing and supporting clemeats for the dowel bars, as shown on the Drawings. ‘The installing template shall be metal plate of adequate rigidity approved by the S.0,, cut to the required depth and crown of the slab and having a length 10 mm less than the required length of the joint. It shall be slotted from the bottom as necessary to permit removal. le means shall be provided on the template for facilitating its removal, ‘One half length of each dowel bar shall be thoroughly coated with a 200 pen bitumen blended with ereosote oil or other material as approved by the $.0. A dowel sleeve shall be fitted on to the coated end of each dowel. The dowel supports shall be. constructed so as to hold dowels in correct alignment, both vertically and horizontally, subject to a tolerance of not more than 1 in 100. When assembled, the top of the installing template shall be about 5 mm above the top of the preformed filler. The filler shall be vertical and shall be in a plane at right angles to the centre line of the road, subject to a tolerance of ‘bot more than 1 in 500 ‘The joint assembly shall be placed so that the installing template is on the side of the filler remote from pouring operations. The top of the filler shall be 10 mm below the required conerete surface, and the bottom shall rest on or extend slightly into the underlying pavement course. The assembly and its installation shall have been approved by the S.0. before any concrete is placed against it Stakes for supporting the installing template shall be of a cross-section and length satisfactory to the 8.0, 552 Transverse Contraction Joints Transverse contraction joints shall consist of planes of weakness created by forming or eutting grooves in the surface of the pavement and, when shown ‘on the Drawings, shall include load transfer dowel bar assemblies. 85-10(IKR/SPI/1988) 5521 Planes of Weakness (@) Sawn Grooves When sawn grooves are specified they shall be sawn in the concrete after its initial set. Grooves shall be at right angles to the centre line of the pavement, shall be true to line and shall have the width and depth shown on the Drawings. All joints shall be sawn before uncontrolled shrinkage cracking takes place but not until the conerete has hardened to the extent that tearing and raveling is not excessive, usually 4 to 24 hours after placing. If extreme conditions exist which make il impracticable to prevent erratic cracking by carly sawing, formed grooves shall be used. Any procedure for sawing joints that results in premature and uncontrolled ‘eracking shall be revised immediately by adjusting the sequence of cutting the joints oF the time interval involved between the placing of the concrete or the removal of the curing medium and cutting of the j (b) — Fonned Grooves ‘When formed grooves are specified, they shall be made by depressing an approved tool or device into the soft, freshly laid concrete. ‘The tool or device shall remain in place until the concrete has attained its initial set and then be removed without disturbing the adjacent concrete. The line, width and depth shall be as shown on the Drawings. 5522 Load Transfer Assemblies Load transfer assemblies for transverse contraction joints shall be as shown on the Drawings. They shall be of similar construction to the assemblies for transverse expansion joints except that no joint filler shall be required and, consequently, no installing template shall be used. 553 Longitudinal Joints Longitudinal joints shall be constructed as shown on the Drawings. Planes of weakness shall be created by forming or cutting grooves as previously specified. Tic bars across a longitudinal joint shall be placed perpendicular to the joint and shall be rigidly supported as shown on the Drawings. The bars shall not be painted or coated with bitumen or other material When adjacent lanes of pavement are constructéd separately, steel side forms shall be used which will form a key along the longitudinal joint as shown on the Drawings. 554 ‘Transverse Construction Joints Concreting operations shall be planned such that transverse construction joints shall be constructed at designed transverse expansion or contraction joints. So-1L(IKR/SPI/1988) ‘Transverse construction joints shall be keyed or butt joints formed by placing, suitable bulkheads approved by the $.0. When there is an interruption of more than 30 minutes in the concreting operations, a transverse construction joint shall be constructed. As far as is practicable, this construction joint shall be formed at a designed transverse ‘expansion Or contraction joint. ‘When this is not possible, transverse construction joints shall be constructed at least 3 metres from all transverse expansion or contraction joints. In such cases, tie bars 12 mm in diameter and 1 metre long at 600 mm centres shall be placed at the transverse construction joints. Wire fabric or bar mat reinforcement shall extend across all such transverse construction joints 55S Sealing Joints Joints shall be sealed-as soon after complotion of the curing period as feasible and before the pavement is opened to traffic, including construction traffic. Immediately prior to sealing, each joint shall be thoroughly cleaned of all forcign material, including membraie curing compound, and the joint faces shall be clean and surface dry when the scal is applied. ‘The scaling material shall be applied in accordance with the dimensions shown, con the Drawings or as directed by the S.O. Scaling material to be applied hot shail be stirred. during beating so that localized overheating, does not occur. ‘The pouring shall be done in such a manner that the. material will not be spilled on110 the exposed surfaces of the concrete. Any excess material on the surface of the concrete. pavement shall be removed immediately and the pavement surface cleaned. The use of sand or similar material as a cover for the seal will not be permitted Preformed compression seals for sealing joints shall be of the cross-sectional dimensions shown-on the Drawings. Seats shall be installed using suitable tools, without elongation, and secured in place with.an approved adhesive which shall cover both sides Of the concrete joints. ‘The seals shall be installed in a compressed condition and shall at time of placement be bolow the level of the pavement surface by approximately 5mm. The seals shall be in one piece for the fell width of each transverse joint. ‘Notwithstanding the above, all sealants shall be applied or installed in e accordance with the manufacturer's instructions or recommendations. 556 Concrete Saw When. sawing.of-joints is specified, the Contractor shall provide. sawing, equipment adequate in number of units and power to complcte the sawing with a water-cooled diamond edge saw blade, or an abrasive wheel, to the required dimensions and at the required rate. The Contractor shall provide at least one stand-by saw in.good working order. An ample supply of saw blades shall be ‘maintained at the site of the work at all times during sawing operations. The Contractor shall provide adequate artificial lighting facilities for night sawing. All ofthis equipment shall be on the job bafore and continuously during ‘concrete placement.56 56.1 56.2 56.21. 5622 (KR/SPI/1988) SURFACE TEXTURE Texture of Running Surfaces After the final regulation and before the application of the curing membrane, the surfaces of concrete slabs to be used as running surfaces shall be brush- textured in a direction at right angles to the centre line of the carriageway. ‘The type of brush and method of application for surface texturing shall be approved by the S.O. based on trial brushing to be conducted by the Contractor. The texture depth shall be determined by the sand patch test as described herein. The average texture depth for cach set of 10 tests shall not be less than 0.75 mm_ and riot more than one test of each set shall show a texture depth of less than 0.65 mm, In no case shall the maximum texture depth exceed 2 mm, Measurement of Testure Depth : Sand Patch Method Apparatus i ‘A cylindrical container - 25 ml capacity. ii) A lat wooden disc 64 mm in diameter with a hard rubber dise, 1.5 mm thick, stuck to one face, the reverse face being provided with a handle. ii) ~ Dry natural sand passing a 300 um B.S. sieve and retained on a 150 um BS: sieve. Method « ~ ‘Tho’surface to be measured shall be dried, any extrancous mortar and/or loose material removed, and the surface swept clean using a wire brush both at right angles-and parallel to the centre line of the carriageway. ‘The cylinder shall be filled with the sand, tapping the base three times onva.hard surface to ensure ‘compaction, and striking off the-sand, level with'the topiof the cylinder. The sand shall be poured into a heap'on:the surface to be tested. The sand shall be spread over the surface, working'the disc with its face Kept flat, in a circular motion so that the sand is spread into a circular patch with the surface depressions filled with sand to the level of the peaks. ‘The diameter of the patch shall be measured to the nearest 5 mm, The texture depth in mm of concrete surfaces shall be calculated as :- 31000 where D is the diameter of the of the patch in mm. DxD87 58 (IKR/SP3/1988) ROUNDING OF EDGES Where shown on the Drawings or directed by the S.0., edges of concrete slabs shall be rounded as follows. After brush texturing but before the concrete, has altained its initial set, top ‘edges of concrete slabs shall be worked with an approved tool and rounded to a radius of 5 mm, A well defined and continuous rounded edge shall be produced and a smooth, dense mortar finish obtained. At all transverse joints, any tool marks appearing on the slab adjacent to the joints shali be eliminated by brooming the surface. In doing this, the rounding of the edge of the slab shall not be disturbed. All concrete on top of joints shall be removed completely. CURING ‘The exposed surfaces of concrete pavement shall be cured immediately after surface texturing and rounding of edges by treating with a curing compound fulfilling the requirements of Sub-Scction 52.6. It shall be mechanically sprayed on to the.surface at a rate of 0:22 to 0.27 litre per square metre using afine spray. The mechanical sprayer shall incorporate an efficient mechanical device for continuous agitation and mixing of the compound in its container during spraying. For the sides of slip formed slabs or when the side forms are removed within the curing period, and for small areas where a mechanical distributor cannot be used, the compound shall be sprayed by hand lance at a rate of 0.27 to 0.36 litre per square metre. ‘The compound shall form a uniform, continuous, coherent film that shall not ‘crack oF peel and.shall be free from pin holes or other imperfections. If discontinuities, pin holes or abrasions exist, an additional coat shall be applied ‘within 30 minutes to the affected areas. Necessary precautions shall be taken to cnsure proper curing at the joints and that none. of the curing compound, centers joints which are to be sealed with joint sealing compounds. Rope of moistened paper, fibre or other suitable material shall be used to seal the top of the joint opening, and the consrete in the region of the joint shall be sprayed with curing compound immediately after the rope seal has been installed. Approved stand-by facilities or approved alternative methods for curing ‘concrete pavement shall be provided at a readily accessible location at the site of the work for use in the event of mechanical failure of the spraying ‘equipment or any other conditions which may prevent eorreet application of the membrane curing compound at the proper time. In the event of a failure of the regular spraying equipment, the paving operation shall be stopped, and the stand-by or alternative curing method shall be used on the remaining portion of the paving already placed. Concrete surfaces to which membrane curing compounds have been applied shall be adequately protected for the duration of the entire curing period from pedestrian and vehicular traffic, except as required for joint sawing operations and surface tests, and from any other cause which will disrupt the continuity ofthe membrane. The curing membrane so formed shall be maintained intact for a period of not less than fourteen (14) days. Im addition, the entire surface shall be protected from the effects of solar radiation by the use of frames covered with material with heat and rain 5-14(UkR/SPS/1988) deflecting properties for not less than 4 hours after application of the curing ‘compound. Notwithstanding the foregoing, concrete surfaces which are subjected to heavy rainfall within 3 hours'after the curing compound has been applied sball be resprayed, all as specified above at no additional cost. Concrete liable to be affected by running water shall be adequately protected from damage during the setting period. 59 REMOVING FORMS Forms shall not be removed until the freshly placed conerete has set for at least 6 hours. The forms shall be removed carefully so as to avoid damage to the pavement, ‘As soon as forms are removed, the ends ofall expansion joints shall be cleaned of concrete and the full width of the filler exposed for the full depth of the slab. Any areas showing a minor degree of honeycombing shall be repaired with 1:3, cement mortar. Where the S.O. considers that a major degree of honeycombing is present, the work shall be considered defective and shall be removed and replaced at the expense of the Contractor. In such cases, the section of concrete removed shall be to the full width and depth of the slab and at least 3 metres long, 5.10 OPENING TO TRAFFIC No pavement shall be opened to any traffic earlier than twenty-cight (28) days from the completion of concreting. ‘The Contractor shall erect and maintain suitable barricades and shall employ watchmen to exclude public traffic and that of his employees and agents from the newly constructed pavement. These barriers shall be arranged so as not to interfere with public traffic on any lane intended to be kept open and necessary signs and lights shall be ‘maintained by the Contractor clearly indicating any lanes open to traffic. Where, as shown on the Drawings, it is necessary to provide for traffic across the pavement, the Contractor shall, at his own expense, construct suitable and substantial crossings to bridge the newly constructed conerete pavement for as long as the S.O. shall direct. Any part of the pavement damaged by traffic or other cause prior to its final acceptance shall be repaired or replaced all at the expense of the Contractor in a manner suitably satisfactory to the $.0. Sal TREATMENT OF MANHOLES AND GULLIES Manhole covers, gullies and their frames shall be isolated from the main pavement slab as shown on the Drawings and their surrounds cast in separate operations. S5-15(IKR/SPI/1988) Manholes and gully recesses shall be formed by casting the main slab against formwork boxes with vertical sides, placed and fixed accurately. ‘The formwork boxes shall be removed before the concrete around the manhole or gully cover is to be placed and preformed joint filler, 20 mm thick, fixed to the slab edges 50 exposed. This shall be to the full depth of the slab allowing for the depth pf the groove required for sealing. Alternatively, the recesses maybe sawn Out after the concrete has hardened. Reinforcement shall be placed as shown on the Drawings and concrete placed hhy hand in the space between the main slab and the manhole or gully frame, ‘This concrete shall be of the same grade as that of the main slab, and the mix shall be modified as necessary to permit full compaction by the methods aidopted. saz HORIZONTAL ALIGNMENTS, SURFACE LEVELS. AND SURFACE REGULARITY ‘The alignment, levels and regularity of the finished surface shall be in compliance with Sub-Section 44 of this Specification, 85-16Plena otc: Pusat Percetakan, Cavangan Pengurusah Korport, n bu Rejabat JIG Kula Lumpus 12106i